Apparatus for forming metal

ABSTRACT

The apparatus allows a metal blank which, in one embodiment, comprises a plurality of bars held in parallel relationship, to be formed into a twisted and bowed shaped object (4) which is referred to in the art as a basket. The forming can be achieved without the need for heating of the metal blank or high powered drive means and so, in one embodiment, can be formed by cold forming and the apparatus can be manually driven. The apparatus can also be adapted to form metal blanks into other forms by the fitting of appropriate forming tools.

This application is a 371 of PCT/GB96/02817, filed Nov. 18, 1996.

BACKGROUND OF THE INVENTION

The invention which is the subject of this application relates toapparatus for use in forming metal into shapes or articles by rotationof an element of the apparatus. Particularly, but not exclusively, theapparatus is for use in forming metal bars which are joined together attheir ends, into a twisted and enlarged shape which is referred to fromhereonin as a basket shape and is illustrated in the accompanyingdrawings.

At present, there is apparatus available which can perform the requiredfunctions of twisting and applying a compression force to metal bars toform the same into a basket shaped article. However, this apparatus isusually relatively complex and relies upon the provision of a hydraulicsystem to enable the forces which are required to be applied to beprovided. The requirement for the hydraulic systems to be providedrender the apparatus which is conventionally available to be expensiveand hence, in turn, the articles which are formed using this apparatusare expensive to purchase. When one considers the materials from whichthe articles are manufactured is relatively cheap, it is the expense ofthe apparatus which is currently available, which causes the price to beincreased. Furthermore, the expense of purchase of the apparatus meansthat the size and volume of manufacturer of these articles are requiredto be on a relatively large scale and there is at present no facility orapparatus available which can be used to form articles such as basketswhich can be economically used by manufacturers of formed metalarticles.

An alternative type of apparatus exists which does not utilisehydraulics but requires each of the bars of a blank to be bentseparately prior to being joined together, whereupon the blank is thentwisted in one direction. However, this process is time consuming aseach bar has to be bent to the same degree and then joined together toform the blank.

The aim of the present invention is to provide apparatus which allowsarticles such as baskets to be formed without the need for hydraulicsystem to be provided but in a form which allows a quality and ease ofmanufacture of these baskets to be maintained if not improved.

SUMMARY OF THE INVENTION

The present invention, in a first aspect, provides apparatus for formingmetal from a blank form, said apparatus comprising a first locationportion for holding one end of the blank in a fixed position and, asecond, rotatable location means for location of the other end of theblank characterised in that said location means is rotatable in a firstdirection with the location means maintained in a first positionrelative to the longitudinal axis of the blank and a second directionwherein the location means is movable along the longitudinal axis of themetal blank.

In a preferred embodiment the blank is formed from a plurality of barssecured together in a parallel relationship.

Typically the movement of the second position of the location means istoward the first location portion.

Preferably as the location means is rotated in the second direction thelocation means moves axially along the longitudinal axis of the blank.

In use, the rotation of the location means in the first directionimparts a twisting of the blank such that when the rotation of thelocation means in the first direction is complete, the metal blank is ina twisted condition. The rotation of the location means in a second,reverse direction, causes the metal bars of the blank to be separatedincreasingly as the position of the location means is moved inwardlytowards the fixed location means. This movement causes each of the metalbars to move outwardly to form a bulbous shape and, at the same time,the degree of twist of the blank is changed such that the final shapecreated is bulbous with each of the bars bowing outwardly and each ofthe bars in a partially twisted condition.

In one embodiment, the second location means comprises a rotatable shaftmounted in a barrel, said shaft having a screw thread portion at leastpartially therealong, a means for rotating the shaft and a means forselectively engaging the screw thread with a screw thread on the barrel.In the first rotation direction, the shaft is rotated with the screwthreads disengaged so that the location means is not caused to movealong the longitudinal axis of the blank and, in the second rotationdirection and upon commencement of the second rotation, the screwthreads are engaged such that as the rotation means is moved to move thelocation means shaft in a second direction of rotation, the shaft ismoved relative to the barrel and frame upon which the barrel and thefixed location means are located and hence the rotatable location meansis moved towards the fixed location means by the screw thread movement.

In one embodiment, the rotation means is a handle for manual operationand the engagement means is a rod which is biased towards engagementwith the screw thread portion such that, once the first rotation hasbeen completed, the rod moves to engage the screw thread portionwhereupon the direction of revolution is reversed such that the screwthread engaged therewith moves along the screw thread on the barrel. Inan alternative embodiment the movable location means can be rotated by apowered motor which is controlled to selectively rotate the locationmeans in the required direction and in the required sequence, but theprinciples of operation remain as before.

The position of the fixed location means can be altered to suit thelength of the blank to be formed and typically the size of screw threadselected can be altered to determine the particular form of article tobe created and also in relation to the size of the metal blank to beformed, although it is preferred that the screw threaded portion of thelocation means be a three start thread.

In one preferred embodiment the frame is slotted and the fixed locationmeans are positionable therealong. Typically the slot is or has fittedthereto tapered means onto which a locking screw contacts such that thetapered effect prevents the fixed location means being forced away fromthe blank during formation of the same into a basket.

It is also envisaged that the apparatus can include other components incertain embodiments to allow metal bars to be twisted using theapparatus of the invention and various other forming actions to beundertaken, including the formation of collars to allow the basket to befitted to the twisted bars and also other formations such as scrolls andcircles.

In one embodiment when twisted bars are to be formed the bar can passthrough the fixed location means and also the shaft of the movablelocation means to allow the bar to be fed into the apparatus and twistedat separate and intermediate locations by selective operation of themovable location means in the first direction as the bar is fed into theapparatus and this is a further inventive aspect of the invention.

Specific embodiments of the invention will now be described withreference to the accompanying drawings, wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a metal blank which has been formed into a basketmade using the apparatus of the invention;

FIG. 2 illustrates a metal blank prior to being formed;

FIG. 3 illustrates a perspective view of the apparatus in a firstembodiment of the invention;

FIG. 4A is a front elevation view of the apparatus of FIG. 3 with themetal blank inserted therein;

FIG. 4B is a front elevation view of the apparatus and blank of FIG. 4Aonce the handle has been rotated in one direction;

FIG. 4C is a front elevation view of the apparatus and blank of FIG. 4Bafter the handle has been rotated in the other direction to form theblank into a basket shape;

FIG. 5A is a cross sectional view taken along line 5A--5A in FIG. 4A;

FIG. 5B is a cross sectional view taken along line 5B--5B in FIG. 4A;

FIG. 6 illustrates a further embodiment of the apparatus as described inFIGS. 3, 4A, 4B, 4C, 5A, and 5B;

FIG. 7 illustrates apparatus according to the invention in a secondembodiment for a second purpose;

FIG. 8 illustrates further apparatus for the embodiment shown in FIG. 7;

FIG. 9 illustrates apparatus according to the invention for a third usein one embodiment;

FIG. 10 illustrates the apparatus for the use of FIG. 9 in a differentembodiment;

FIG. 11 illustrates the finished article formed using the various piecesof apparatus of the invention;

FIGS. 12, 13 and 14 illustrate an alternative embodiment of theapparatus;

FIGS. 15 illustrates a further alternative arrangement of the invention;

FIGS. 16A-D illustrate a further embodiment of the basket forming andbar twisting apparatus of the invention;

FIG. 17 illustrates a location means and associated barrel according tothe embodiment of FIG. 16A-D; and

FIG. 18 illustrates a section showing the location means and barrel ofFIG. 17 in engagement.

DETAILED DESCRIPTION OF THE PREFERRED

Referring firstly to FIGS. 1 and 2, there is illustrated a metal blank 2in FIG. 2 which is used to form a basket 4 as shown in FIG. 2 therefrom.As can be seen, in FIGS. 1 and 2, the blank comprises four lengths ofmetal bar 6 which are held in parallel position with the ends of thesame being joined together by means of welding or other means 8 asshown.

FIGS. 3 to 5 illustrate apparatus in one embodiment according to theinvention for use in forming a basket as shown in FIG. 1 and theapparatus comprises a frame 10 upon which is located at one end a fixedfirst location means 12 which is provided on a plate 14 which is held inposition by pin 16. Typically the frame comprises a plurality oflocation points 18 to allow the position of the location means 12 to beselected as appropriate. Towards the other end of the frame there isprovided a rotatable second location means 20 and said location means(12, 20) serve to provide location for the ends of the blank 2 placedtherebetween. The rotatable location mean in this embodiment is mountedon a rotatable shaft 22 and is connected to a manually actuable handle24 but this could equally be replaced by a motor driven arrangement.Also provided on the shaft and to be selectively coupled thereto is ascrew thread portion 26 which is provided in threaded engagement with abarrel section 28 fixed to the frame and through which the shaft andscrew thread portion pass. The rotatable means of the shaft is providedwith a flange 30 which has a protrusion 39 provided thereon for locationselectively in a matching aperture 34 in a flange 35 connected to thescrew thread 26. Also provided on the shaft is lug 36 for selectiveengagement with the flange 30 and, a spring 38, which urges the flange30 towards the screw flange 35.

In use, the blank 2 is placed with an end of the same located in fixedlocation means 12 and the other end in location means 20. Referring nowto FIG. 4, the rotatable shaft 22, flange 30 and handle 24 are rotatedin a first direction with the location protrusion 32 disengaged from theflange 35 such that the location means 20 rotates and, as it rotates,exerts a twisting action on the metal blank 2 to twist the same.Typically, the protrusion 32 and aperture 34 on the flange 35 arearranged such that as the flange 30 is rotated, and is biased towardsthe flange 35 by the spring 38, so when the protrusion 32 is at the sameposition as the aperture 34 it passes into the aperture to engage theflange 35 and screw thread 26 with rotatable shaft 22. At this point,the direction of revolution of the shaft is reversed and the locationmeans 20 is now engaged with the screw thread which moves relative tothe frame 10, upon rotation. Thus the location means, in addition torotating, also moves towards the fixed location means 12 and, as it doesso, the bars 6 of the blank 2 are forced to bow outwardly. At the sametime the degree of twist of the bars 6 is reduced. Thus, when therequired rotation of the location means 20 in the second direction iscompleted, a basket 4 is formed and FIG. 5 illustrates a formed basketwhich has been removed from the location means.

Once the basket has been formed to the required shape as shown in FIG.5, the location means 12 is removed to allow removal of the basket.

Typically, the size of the thread will determine the extent of bowing ofthe bars 6 of the blank but typically the location means 20 is movablein the first rotatable direction by 3/4's--1 revolution and then rotatedin the opposite direction with the screw thread engaged by 1-2revolutions, thus providing the required forming action on the metalblank.

FIG. 6 illustrates a variation of the apparatus of FIGS. 3-5 wherein theprotrusion 32 and aperture 34 of the flanges 30 and 35 of the movablelocation means 20 are replaced by teeth 37, 29 engaged to drive thescrew thread in the same manner as described in relation to FIGS. 3-5.

Referring now to FIG. 7, there is illustrated a further feature of theapparatus of the invention wherein the apparatus described in relationto the rotatable location means 20 is as described in relation to FIGS.1 to 5 but the fixed location means 12 is replaced by a plate 40 havinga slot 42 formed therein. The plate is fixed in position and in thisform the apparatus is for use in forming lengths of bar into a twistedcondition and is performed by moving flange 30 which, in its normalposition for making baskets and pressing collars, lies over lug 36 onshaft 22. When moved, the flange 30 is pulled away from flange 35 andthen turned slightly so that a small notch 36A as shown in FIG. 5 on theflange 30 engages with lug 36. In this form the flanges 30, 35 are keptapart and in a neutral position. In this condition the handle can beused to turn shaft 22 without engagement of the flanges and twisting ofthe solid square bar occurs. When twisting is completed flange 30 can betaken off the notch and returned over lug 36 to make baskets and presscollars once more. If only a portion of the bar is to be twisted, theremainder of the length of the bar can be passed through the aperture 44in the frame 10 and thus, lengths of bar can be twisted using theapparatus of the invention. Furthermore as the shaft 22 has a port 49therein, the bar can be passed through the port 49 to allow the bar tobe fed into the apparatus.

FIG. 8 illustrates a further apparatus for use with the apparatus ofFIG. 7 wherein, if the bar to be formed is longer than the frame 10 atthe portion which is to be formed and twisted is longer than the frame10, then the additional frame 50 can be attached to the frame end 10A.The frame 50 is provided with a bar 52 along which is slidablypositionable a block 54 which can be used to locate the end of the barwhich is to be formed using the apparatus. If required an insert 56 canbe moved into the block 54 for a bar of a smaller section. Thus thisadditional part of apparatus allows the use of the apparatus of theinvention to be extended.

FIGS. 9 and 10 illustrate the apparatus of the invention for a furtheruse in two embodiments wherein a plate 60 replaces the fixed locationmeans and to this plate 60 is located a forming block 62. In FIG. 10 themovable location means 20 and accompanying apparatus is as previouslydescribed but provided in the location means 20 is a push rod 64 with ablock 66 and rotatably mounted lengths 68 such that, in use, in oneembodiment the flanges 30 and 35 are engaged as shown in such thatrotation of the shaft 22 causes the location means 20 to rotate and tomove inwardly as the screw thread 26 is engaged with the frame 10. Asthe location means 20 rotates so the length 68 rotates relative to theblock 66 and, as location means 20 moves towards the forming block 62,so the block 66 is moved in towards the slotted aperture 70 in theforming block 62. This apparatus is used for forming a collar from astrip of sheet metal 74 which is placed between the block 66 and theforming block 62 over the face of the aperture 70, as shown in brokenline, such that as the block 66 is moved into the slotted aperture 70,the strip material is formed into a collar shape between the block 66and walls of the slotted aperture 70. The collar 74, when formed, isshown in FIG. 10. The embodiment of FIG. 9 includes similar components60A, 62A, 64A, 66A, 70A, and a different form of movable location meansand this is described in detail with regard to FIGS. 16A-D, 17 and 18.

FIG. 11 illustrates an article incorporating a basket 4, which is joinedto twisted rods 76 and 78 by means of collars 74, all of which can beformed using the apparatus of the invention.

FIGS. 12, 13 and 14 illustrate the frame 110 in an alternative form witha slot 111 and side rails 114 for the reception of a fixed locationmeans 112 therein. The slot is provided adjacent the side walls on theunderside with sloping protrusions 118 with which a locking means 119provided on the location means 112 can contact to retain the locationmeans 112 in the desired position for forming the basket as previouslydescribed with reference to FIGS. 3-5. As the locking means contacts theprotrusions 118 which slope away from the position of the rotatablelocation means (not shown) so the fixed location means 112 is preventedfrom being forced away from the rotatable location means due to theforces exerted by the twisting and compressing of the blank into abasket as the slope prevents movement of the locking means 119. Thisarrangement replaces the fixed location means 12 of FIGS. 3-5 and hasthe advantage of extra strength and resistance to forces exertedthereon.

FIG. 15 illustrates a further embodiment of the apparatus wherein aclamping means 130 is provided to clamp the collar round the basket asshown.

FIGS. 16A-C illustrate an alternative embodiment of apparatus forforming baskets and 16D shows alternative apparatus for twisting barswhich operates on the same principles as the previously describedapparatus but in this instance the movable location means 222arrangement differs and this is described in detail in FIGS. 17 and 18.In use the procedure is the same as before in that the blank 202 isplaced between fixed location means 212 and movable location means 222as shown in FIG. 16A. The movable location means are then rotated in afirst direction by rotating the handle 230 and in this direction theshaft 228 is disengaged from the barrel 224 so that only rotationalmovement takes place and hence the blank 202 twists as shown in FIG.16B. Upon completion of rotation in the first direction the shaft isengaged with the barrel and rotated in the reverse direction and theengagement causes linear and rotational movement thereby causing bowingof the blank 202 and the bars 206 to separate to form the basket shapeas shown in FIG. 16C.

FIGS. 17 and 18 illustrate the alternative movable location means 222which is engaged with a barrel 224 which is fixed with the frame of theapparatus. On the interior of the barrel is fixed a threaded section226. The movable location means 222 is formed of a shaft 228 with at oneend a socket 234 for the blank and is rotatable by the handle 230 asshown in FIG. 18. Mounted on the shaft and selectively engagabletherewith is a screw threaded portion 232. The blank is engaged in thesocket 234 as before and the handle 230 and shaft 228 rotated in a firstdirection with a rod 236 held by the surface of the screw threadedportion 232 against a biasing spring 238 and thereby disengaging thescrew thread portion 232. When the end of the first revolutionapproaches, the end 240 of the rod, which moves along the screw threadedportion, reaches an aperture 242 in its path, and the biasing spring 238acts to move the rod into the aperture in the screw threaded portion andengage the same so that rotation of the shaft in the reverse directioncauses the screw threaded portion and screw thread on the barrel toengage and hence location means to move relative to the barrel 224towards the other location means and cause the bowing of the twistedblank.

It should also be appreciated that the movable location means 222 ofthis embodiment can be used for any of the other uses previouslydescribed with reference to the earlier figures and one such use isshown in FIG. 16D wherein a blank 290 is held in the fixed locationmeans 212 and passes through the a longitudinal aperture in the shaft228 of the movable location means 222. In this arrangement the rod 236is held against the biasing spring by catch 292 so that the rod cannotmove to an engaging position with the screw threaded portion 232 andhence the handle 230 and shaft 228 can be rotated through severalrevolutions in the first direction to cause the blank 290 to twist asrequired.

Thus, it can be seen, that the apparatus of the invention as describedherein can be used for a plurality of uses and, in one particularembodiment can be used to form a basket and also to form a completearticle including a basket which is joined to twisted rods and all ofthe components are formed using the apparatus of the invention invarious embodiments.

We claim:
 1. Apparatus for forming metal from a blank form, saidapparatus comprising a location portion for holding one end of the blankin a fixed position and, a movable location means for location of theother end of the blank characterised in that said location means isselectively rotatable in a first direction with the location meansmaintained in position relative to the longitudinal axis of the blankand a second direction when the location means is movable along thelongitudinal axis of the metal blank.
 2. Apparatus according to claim 1wherein the blank is formed from a plurality of bars secured together ina parallel relationship.
 3. Apparatus according to claim 1 wherein themovement of the movable location means along the longitudinal axis istowards the first location portion.
 4. Apparatus according to claim 1wherein as the movable location means is rotated in the second directionthe location means moves axially along the longitudinal axis of theblank.
 5. Apparatus according to claim 1 wherein rotation of thelocation means in the first direction imparts a twisting of the blanksuch that when the rotation of the location means in the first directionis complete, the metal blank is in a twisted condition.
 6. Apparatusaccording to claim 5 wherein rotation of the location means in a second,reverse direction, causes the metal bars of the blank to be separatedincreasingly as the position of the location means is moved inwardlvtowards the fixed location means.
 7. Apparatus according to claim 6wherein the movement in the second direction causes each of the metalbars to move outwardly to form a bulbous shape and, at the same time,the degree of twist of the blank is changed such that the final shapecreated is bulbous with each of the bars bowing outwardly and each ofthe bars in a partially twisted condition.
 8. Apparatus according toclaim 1 wherein, the second location means comprises a rotatable shaftmounted in a barrel, said shaft having a screw thread portion at leastpartially therealong, a means for rotating the shaft and a means forselectively engaging the screw thread with a screw thread on the barrel.9. Apparatus according to claim 8 wherein in the first direction ofrotation, the shaft is rotated with the screw threads disengaged so thatthe location means stays in the same axial position and prior to, orupon, commencement of the second rotation, the screw threads are engagedso that rotation causes the shaft and the location means to moverelative to the barrel and the fixed location means.
 10. Apparatusaccording to claim 1 wherein rotation is provided by applying a force toa handle.
 11. Apparatus according to claim 10 wherein rotation of themovable location means is by powered drive.
 12. Apparatus according toclaim 1 wherein the apparatus is provided with engagement means whichare movable between a disengaged position when the movable locationmeans is rotated in a first direction and an engaged position when thelocation means is rotated in the second direction.
 13. Apparatusaccording to claim 12 wherein the engagement means is a rod which isbiased towards the engagement position.
 14. Apparatus according to claim13 wherein the rod is provided such that once the first rotation hasbeen completed, the rod moves to engage the screw thread portion of thelocation means with the screw thread portion on the barrel such thatwhen the direction of revolution is reversed to the second direction thescrew thread engaged therewith moves along the screw thread on thebarrel.
 15. Apparatus according to claim 14 wherein the dimension ofscrew thread can be selected and changed to determine the particularform of article to be created and also in relation to the size of themetal blank to be formed.
 16. Apparatus according to claim 1 wherein theposition of the first location portion can be altered prior to, orduring, the forming operation to suit the length of the blank to beformed and/or the form to be created.
 17. Apparatus according to claim16 wherein the first location portion is fitted in position along a slotin a frame and the slot is tapered to prevent the fixed location meansbeing forced away from the blank during formation of the same. 18.Apparatus according to claim 1 wherein the apparatus includes a catch toprevent engagement means which causes the engagement of screw threads inthe movable location means from engaging during rotation of the movablelocation means in the first direction and thereby allows the formationof a twisted bar.
 19. Apparatus according to claim 1 wherein therotational movement of the movable location means is translated intolinear movement to allow a pressing action to be exerted to form metalblanks into a required form.